Case Studies
These case studies provide a quick and accurate overview of our recent accomplishments. Scroll down, or jump to one of the sections below.
Modular Offices | Environmental Enclosures | Wall Partitions & Demising Walls | Mezzanines | Cleanrooms | Cultivation Rooms
Submit a Case Study
If you are a PortaFab Dealer or Partner Contractor and would like to submit a Case Study, please download and complete the Case Study Worksheet via the link below and forward it to your PortaFab representative. If you have pictures of the construction or finished room/building and can secure permission for us to use these, please provide this information as well.
Modular Office & Inplant Building Case Studies
Two-Story Modular Building
Application: Office Space, Conference Space, Locker Rooms & Quality Testing Lab
Location: Fort Payne, AL
Product: OmniFlex Vinyl Fire & Sound – 10’ lower 9’ upper (90’ x 26’ x 90)
Benefits:
- New office, conference, laboratory and locker room space
- Assistance with construction permits, specifications and approval drawings via our distributor
- Effective utilization of existing space via three-wall, two-story layout
Two-Story Mezzanine Office Building
Application: Offices, training and research space
Location: St Charles, MO
Product: OmniFlex Fire & Sound (gray)
Benefits:
- Allocated new space while minimizing lateral footprint by expanding vertically.
- Distributor coordinated installation of both office walls and mezzanine.
”Quick-Ship” Warehouse Office
Application:Shipping & Receiving Managers Office
Location: Michigan
Product: OmniFlex Fire & Sound (white)
Benefits:
- Quick order and delivery to meet demand
- Minimized cost by using modular electric
- Potential for future reconfiguration
Elevated Plant Supervisors Office
Location: Stevensville, MI
Product: OmniFlex Vinyl Fire and Sound
Benefits:
- Fast delivery and installation due to quick-ship program and modular electrical wiring.
- Elevated office on a mezzanine to provide clear view of entire manufacturing processes.
Quality Inspection Room
Location: South Carolina, US
Application: Glass Manufacturer Inspection Room
Product: OmniFlex 14’ Tall Steel Fire & Sound
Benefits Provided:
- Temperature-controlled enclosure with particle filtration to improve product quality and aid inspection process.
- Extra-high walls to accommodate large equipment inside, while installing the building neatly underneath existing bridge crane outside.
- Steel framing for structural integrity and Fire & Sound panels for thermal control.
Modular Office Complex
Location: Charlotte, NC
Application: Modular Offices
Product: OmniFlex System 9-Feet Tall
Benefits Provided:
- Integrated new office walls with existing walls matching in color and appearance.
- Noise reduction inside offices from nearby manufacturing processes with Fire and Sound panels.
- Modular advantages including expandability, ability to re-locate and versatility of structures for a dynamic and growing company.
Modular Break Room & Showroom
Location: Sturtevant, WI
Application: Multi-Purpose Inplant Building
Product: OmniFlex (18-foot tall)
Benefits:
- Extra-tall windows with open view of manufacturing floor.
- Reduced labor costs by utilizing 3-wall design & suspended ceiling system.
- 18-foot high walls and open interior floor plan to accommodate large demonstrations.
Modular Communications Closets
Customer: Automobile Manufacturer
Application: Telecommunications and Network Storage
Product: 10' x 10' Preassembled Buildings
Benefits Provided:
- Reduced time and labor by using prefabricated modular units.
- All-welded aluminum framework provided structural integrity for locating the buildings.
- Units outfitted with customized electrical requirements to meet application specifications.
Training Center with Glass Wall Partitions
Client: Volkswagen Academy in Chattanooga, TN
Products: OmniFlex (15 feet tall), Full Glass Windows and Fire & Sound Panels
Benefits Provided:
- Attractive appearance
- Flexibility to create different sized training rooms
- LEED points for the construction project
- Quick turnaround time
Parts Storage & Distribution Area
Application: 2,555 sq ft in-plant building with secured storage area.
Product: OmniFlex with Fire & Sound Panels
Benefits Provided:
- Flexibility to move in future
- Secure, enclosed area with sound control
- Minimal disruption to plant during construction
Two Story In-Plant Office Building
Application: New two story modular office within existing manufacturing plant facility
Product: OmniFlex
Benefits Provided:
- Expanded usable office space without enlarging existing footprint
- Engineering and operations teams given direct access to plant operations
- Effectively used vertical square footage
Warehouse Offices & Storage Space
Application: 2,778 sq. ft. office complex, consisting of two story and single story offices with storage decks.
Product: Series 300
Benefits Provided:
- Tied into existing modular offices
- Attractive appearance
- Maximized floor space
Prefab Office Space
Application: 2,430 square foot 2-story office
Product: Series 300
Benefits Provided:
- Adapt design to needs without seriously impacting budget or time line
- Professional appearance
- Sound control
Sound-Resistant Modular Office
Application: Two-Story Office with Sound-Resistant Properties
Product: OmniFlex
Benefits Provided:
- Effective sound control
- Ability to re-locate easily
- Minimal disruption to existing business
Load-Bearing Modular Building
Application: Modular Offices and Lunchroom with Storage Decks
Product: Series 300 with Fire & Sound Wall Panels
Benefits Provided:
- Effective sound control
- Ability to re-locate easily
- 2-Story design to maximize space utilization
Equipment / Machine Enclosure
Location: Elk Grove Village, IL
Application: Thermal Enclosure to Protect High-Tech Equipment
Product: OmniFlex Insulated Panels
Benefits Provided:
- Cleaner alternative to modern construction
- Insulated walls for optimal thermal control
- Flexibility of reconfiguration in the future
Control Pulpit for Steel Mill
Location: Warsaw, KY
Client: North American Stainless
Product: OmniFlex Steel Fire & Sound
Benefits Provided:
- Tall windows provide 180 degree unobstructed view
- Heightened platform allows max visibility of facility
- Climate-controlled, sound-proof room protects operator from extreme steel mill environment
Laboratory and Office Space
Location: Chicago, IL
Client: Vegetable Juices, Inc.
Product: OmniFlex Fire & Sound
Benefits Provided:
- Two-story building to house lab and office space
- Odors contained within lab on ground floor
- Contemporary design and appearance
Modular Electric Wiring
Application: Office and Conference Room
Product: Modular Electric Wiring System
Benefits Provided:
- Rapid installation
- Reduced project cost
- Flexibility of reconfiguration in the future
2-Story Inplant Office Building
Location: Minneapolis, MN
Application: Warehouse Manager Offices
Product: OmniFlex Fire & Sound Panels
Benefits Provided:
- Minimized space by building vertically
- Reduced project cost
- Quick installation
Training Area and Conference Space
Client: Los Angeles Police Dept.
Application: 2-Story Modular Building
Product: OmniFlex Fire & Sound (Steel Exterior, Vinyl Interior)
Benefits Provided:
- Space for training purposes and meetings
- Security and adherence to local building codes
- Saved lateral space by building vertically
Secured Storage Enclosure
Location: Minneapolis, MN
Application: 3-Wall Modular Building
Product: OmniFlex Steel Fire & Sound Panels
Benefits Provided:
- Minimized space by building vertically.
- Reduced project cost with 3-wall design.
- Emphasized "green" building standards.
Industrial In-Plant Office Building
Location: Toronto, Canada
Client: A1 Label
Product: Series 300 Fire & Sound Panels (12-feet high)
Benefits Provided:
- Extra tall ceiling and wide doors to accomodate large equipment.
- Sound-resistant wall panels to minimize noise from surrounding printing machines.
- Open atmosphere as a result of large surrounding windows.
Equipment Supply Depot
Location: Bome, Equatorial Guinea
Client: Hess Corporation
Product: OmniFlex F&S
(Vinyl Exterior and FRP Interior) 35' 11 x 99'3"
Benefits Provided:
- Utilized PortaFab's installation network
- FRP Walls for durability and cleanability for the shower and locker room
- Incorporated plumbing chases within structure
- 125 PSF Loadbearing roof to utilize existing overhead space
Environmental Enclosures
Paint Finishing Enclosure
Location:Gwenner, ND
Application: 32’ X 88’ X 24’ Tall Paint Finishing Enclosure
Product Used: PortaMax 4-5/8 & OmniFlex Wall Systems
Benefits Provided:
- Effective environmental control
- Timely installation with minimal disruption to plant
- Met 24’ height requirements
Pharmaceutical Sampling Booth
Location: Greeneville, IL
Client: Mallinckrodt Pharmaceuticals
Product: Cleanline S3000 with FRP Wall Panels
Benefits:
- Met requirements for ISO 8 and ISO 7 level classifications
- Structure designed and built to comply with EU standards
- Integrated controls for high-speed conveyor system to create automated process
- Dedicated HVAC system to maintain temperature and humidity requirements
CMM Room, Lab and Office Space
Location: Western Canada
Distributor: Central Warehouse Equipment
Application: Coordinate Measuring Machine Enclosure, Lab Space & Offices
Product: OmniFlex Vinyl (white)
Benefits:
- Effective environmental control to protect processes within CMM room
- Additional office space by expanding vertically
- Improved throughput through addition of QA/QC lab
- Maximize vertical space, minimizing impact to valuable plant floor space
Coordinate Measuring Machine (CMM) Enclosure
Location: Houston, TX
Application: CMM Room Enclosure
Product: OmniFlex Steel with Fire & Sound Panels (Champagne)
Benefits Provided:
- Steel surfaces for ease of cleanability, durability and non-shedding surfaces to reduce particulates.
- Temperature and airflow controlled environment to provide reliable testing and measurement.
- Extra-tall walls and roll-up door to ease transfer of large equipment in and out of enclosure.
Food Process Enclosure
Customer: Worldwide Medical, Pharmaceutical and Nutrition Company
Application: Containment Area for Mixing & Bottling Baby Formula
Product: PortaMax Aluminum System Featuring Epoxy-coated Aluminum Panels (Fire and Sound) with Moisture-Resistant Gypsum (17’4” - 20’ tall because of the ceiling truss)
Benefits Provided:
- Epoxy-coated surfaces comprised of moisture-resistant gypsum to withstand water penetration during cleaning process.
- Floor to ceiling wall system seated upon 6-inch high curb (to contain excess water during wash down).
- Seamless integration of walls with existing conveyor system, concrete columns and trussed ceiling.
Modular Wall Cladding at Fish Hatchery
Location:: Huntsdale, PA
Application: Composite Panel Wall & Ceiling Cladding
Product: Furring 500 FRP over ½” thick Plywood
Benefits:
- Customized solution to meet the particular needs of our client.
- Seamless and durable wall and ceiling cladding to withstand cleaning and high moisture environment.
- Economical alternative to conventional construction.
Painting Process Enclosure
Location: Rome, GA
Client: Suzuki
Product: OmniFlex Steel-Faced Panels (16 feet tall)
Benefits Provided:
- Insulated walls for optimal thermal control
- Improved product yield
- Integration with existing conveyor system
Battery Storage Enclosure
Customer: A123 Systems
Location: Detroit, MI
Product: PortaMax 458 steel stud (23 feet tall)
Benefits Provided:
- Insulated walls for optimal thermal control
- Removable exterior walls
- Doors located for aisle access
CMM Room / Equipment Enclosure
Location: Columbus, Indiana
Client: Toyota
Product: S3000 with Fire & Sound Wall Panels
Benefits Provided:
- Humidity and temperature control
- Ability to relocate easily
- Sound insulation
Powder Coating System Enclosure
Location: Grand Rapids, MI
Client: American Seating
Product: OmniFlex (56' x 58' x 16' Tall)
Benefits Provided:
- Effective environmental control
- Effective sound control
- World class appearance
Equipment Enclosure / Modular Construction
Location: Fairfield, Illinois
Application:Equipment Enclosure Room, Conference Room, Plant Separation
Product: XTRA TALL Wall Systems, Series 300
Benefits Provided:
- Consistent appearance throughout plant
- Effective environmental control
- Flexibility to relocate
Laser Equipment Enclosures
Location: Minneapolis, MN
Client: Innovative Laser Technologies, Inc.
Product: OmniFlex Fire & Sound
Benefits Provided:
- Walls made of fire retardant materials
- Open design, utilizing pre-existing lighting & sprinkler system
- Laser safety glass windows in doors
Demising Walls for Warehouse Segregation
Location: Marion, Kentucky
Client: Siemens
Product: XTRA TALL Wall System (270' Long x 21'-24' tall)
Benefits Provided:
- Protect sensitive machinery
- Improve appearance of plant to visitors
- Increase space utilization
Environmental Control
Location: Grand Rapids, MI
Application: 30' high x 630' long wall in manufacturing plant
Product: PortaMax XTRA TALL Wall System
Benefits Provided:
- Effective environmental control
- Clean installation process allowed for continuous operation
- Flexibility to re-locate and re-use in future
Medical Equipment Storage
Location: Joliet, IL
Application: Climate-Controlled Area to House Medical Equipment
Product: SteelSpan Wall System (350 lineal feet, 28 ft tall)
Benefits Provided:
- Proper R-value of insulation to house equipment
- Fast installation
- Area accessible by fork lift via high-speed roll up doors
- Flexibility of modular wall system
Thermal Equipment Enclosures
Location: Midwest US
Application: Thermal Equipment Enclosures
Product: SteelSpan 28-Foot Tall
Benefits Provided:
- 28-foot tall thermal enclosures for equipment and manufacturing processes
- Ability to reconfigure the space based on client needs
- Office space allowing facility engineers to be in closer proximity to manufacturing
- Accelerated depreciation
Coordinate Measuring Equipment Enclosure
Location: Cleveland, NC
Client: Hersey Meters
Product: PortaMax 458s 20' Tall Thermal Steel Wall Panels
Benefits Provided:
- Thermal control to protect equipment & processes
- Panel construction featuring an R-value of 20
- Full-height windows for viewing of processes & equipment
- Ability to offer factory tours without disruption of processes
CMM Equipment Enclosure
Customer: Mining Equipment Manufacturer
Application: Thermal-controlled CMM equipment enclosure
Product: OmniFlex Fire and Sound (16-foot tall)
Benefits Provided:
- Building constructed to withstand tight tolerances for measuring
- Roll up doors to allow safe passage of large equipment while maintaining environmental control
- Integrated wall system with bridge crane for use in transferring large equipment
Wall Partitions & Demising Walls
Full Glass Wall Partitions
Client: Fitzgerald Trucking
Product: OmniFlex Vinyl Fire and Sound (8-1/2’ tall)
Benefits Provided:
- Reduced debris and installation timeframe by ordering pre-cut panels
- Flexibilaity to reconfigure if needs change
- Installation completed during normal business hours
Freestanding Industrial Wall Partitions
Client: AeroVironment, Inc.
Product: OmniFlex with Freestanding Wall Panels
Benefits Provided:
- Segregated Work Areas
- Provided Visibility Into Work Areas
- Lower Cost than Standard Furniture Alternative
- Custom Painted to Match Existing Structures
Medical Equipment Packaging Enclosure
Client: Crown Cork & Steel
Product: SteelSpan (28' tall)
Benefits Provided:
- Divided packaging area from the rest of the facility.
- Contained noise and particles.
- Operator could oversee production from outside of packaging area.
Separation Wall & Bulletin Board
Client: Hyundai North America
Product: OmniFlex
Benefits Provided:
- Separated space
- Provided meeting area
- Provided posting vehicle
Free-Standing Wall Partitions
Client: Novartis Pharmaceuticals Corp.
Application: Separation of Manufacturing Space
Product: OmniFlex (76 Linear Feet & 80" tall)
Benefits Provided:
- Separated manufacturing space
- Aided in achieving FDA compliance
- Blended well with existing partitions
Demising Walls for Plant Separation
Location: Plainfield, NJ
Client: PIM Brands, LLC
Product: SteelSpan Wall System (30 foot tall)
Benefits Provided:
- Separation of manufacturing and distribution areas
- Fast installation
- Compliance with local building codes
Mezzanine Case Studies
Modular Offices on a Mezzanine
Location: Ames, IA
Application: Modular Offices on a Mezzanine
Product: 3” OmniFlex wall system with Modular Wiring Package
Benefits Provided:
- 3 new offices, each complete with electrical, HVAC, windows and exterior doors
- Minimized lateral footprint by expanding vertically within production facility
- Mezzanine design which allowed existing processes to continue underneath
- Flexibility for future reconfiguration by utilizing modular systems
Mezzanine Storage Solution
Location: Colorado Springs, CO
Application: Mezzanine Storage and Laboratory Space
Product: OmniFlex Fire and Sound - Gray
Benefits Provided:
- Expanded vertically by incorporating a mezzanine design.
- Storage solution adhered to local fire code and did not require expansion of existing facility.
- Ability to reconfigure layout and adapt to future business changes or expansion.
- Turnkey solution featuring fire suppression, HVAC, lighting and engineering & building permits.
Elevated Warehouse Control Rooms
Client: Waste Management, Inc.
Location: New York
Application: 67" x 10" and 67" x 30' control rooms elevated on 25' high mezzanine
Product: OmniFlex
Benefits Provided:
- Safe, comfortable work area
- Installation with minimal disruption
Modular Office on Mezzanine
Client: Master Lock
Product: OmniFlex (40' x 100')
Benefits Provided:
- Added space within plant and better view for foreman to monitor activity
- Provided sound reduction to improve worker productivity
- Met complex building code requirements within budget
Offices on Mezzanine
Location: Beaverton, OR
Client: NIke
Product: OmniFlex Fire & Sound (14 foot tall)
Benefits Provided:
- Integrated structure with existing mezzanine to minimize space
- Saved cost by utilizing existing lighting, ceiling & fire protection
- Flexible design based on local building codes
- Ease of future reconfiguration if needed
Military Training Complex
Location: Virginia, US
Application: Military Training Complex
Product: OmniFlex Steel Fire and Sound
Benefits Provided:
- Support from Distributors to Coordinate Multiple product Lines
- Variety of indoor enclosures for multiple training scenarios
- Deployable and Flexibility to modify training area for enhanced training value
- Integration of non-standard equipment within structure
Air National Guard Facility
Location: Southern, United States
Application: Offices, Conference Room and Classroom on a Mezzanine
Product: OmniFlex Fire and Sound
Benefits Provided:
- 2-story mezzanine with offices and training areas
- Financial savings with modular construction
- Ease of procurement
- Integration of modular systems with mezzanine manufacturer
Print Process Enclosure Built on Mezzanine
Customer: Print and Packaging Manufacturer
Location: Southern CA
Application: Printing process enclosure and office space integrated into mezzanine
Product: OmniFlex (Gray) Fire and Sound
Benefits Provided:
- Temperature and humidity controlled & dust-free enclosure
- Increased storage space utilizing mezzanine
- Integrated new buildings with existing buildings by matching height and enclosed catwalk
- Incorporated laminated glass windows to reduce noise of surrounding environment
Cleanroom Case Studies
Cleanroom for Medical Device Manufacturing
Product: Series 300 Vinyl Fire and Sound / Furring 500
Application: ISO 8 / Class 100,000 Vestibule and Cleanroom
Benefits:
- Minimal impact to facility during installation.
- Environmental control for ISO 8 validation.
- Coordination with construction trades for efficient construction process.
E-Liquid Manufacturing Clean Room
Location: Grand Rapids, MI
Application: E-Liquid Manufacturing Cleanroom
Product Line: OmniFlex Two-Story Building
Benefits:
- Provided a clean environment that met ISO 6 (Class 1,000) classification
- Fast and low mess installation allowed client to maintain manufacturing progress, uninterrupted during the new construction project.
- Flexibility to expand or even re-locate the building due to future growth or changes in business needs.
Cleanroom for O-Ring Manufacturing
Location: Lexington, KY
Application: Cleanroom ISO 7 (Class 10,000)
Product: Series 300 with FRP Fire & Sound Panels
Benefits:
- A complete, turn-key solution through PortaFab’s existing network of cleanroom contractors.
- Multiple clean environments in which to contain each stage of the manufacturing process.
- ISO 7 (Class 10,000) classification.
- Recirculating airflow design and positive pressure.
Semiconductor Cleanroom
Location: Colorado Springs, CO
Application: Cleanroom
Product: Series 300 & P2000 ESD (electro-static discharge) Epoxy-Coated Aluminum Skins on Fire & Sound Panels.
Benefits Provided:
- Anti-static wall system to maintain standards for semiconductor fabrication.
- Double-wall system to ensure maximum envirionmental control.
- Removable wall section to ease transfer of large equipment.
- Use of P2000 wall system for economical construction of gowning area and air shower entry.
Cleanroom for Polymers Research
Location: Cleveland, OH
Application: Cleanroom (ISO 7 & ISO 8)
Product: Series 300 with Vinyl Fire & Sound Panels
Benefits Provided:
- Multiple ISO classifications for different areas including gowning room, storage area and main lab.
- High visibility windows to serve as client demonstration area.
- Complete turn-key solution through PortaFab’s involvement with general contractor, pre-construction meetings and on-site supervision during installation.
Underground Cleanroom
Location: Lead, South Dakota
Application: Controlled Environment
Product: OmniFlex 11' Tall with Steel/Poly/Steel Panels
Benefits Provided:
- Thermal control to protect expensive research equipment
- Dust and particulate-free environment to minimize the possibility of contamination
Class 100 (ISO 5) Cleanroom
Location: Opelika, Alabama
Client: Ampex Recording Media
Product: CleanLine S3000 (30,000 S.F.)
Benefits Provided:
- Flexibility
- Class 100 / ISO 5 conformance capability
Class 1,000 (ISO 6) Cleanroom
Location: Englewood, Colorado
Client: Pozzetta Micro Clean
Product: CleanLine S3000 with Flush Windows (1,000 sq ft)
Benefits Provided:
- Speed of completion
- Corporate showpiece for attracting new business
Class 100,000 (ISO 8) Industrial Cleanroom
Location: Lafayette, Indiana
Client: Caterpillar
Product: OmniFlex
Benefits Provided:
- Allowed operation to comply with quality guidelines from major customer.
- Integrated with conveyors and bridge crane with minimal plant disruption.
Cleanroom for Electronics Manufacturing
Location: Springboro, Ohio
Client: Pioneer Electronics
Product: OmniFlex (2,000 ft)
Benefits Provided:
- Improved quality
- Increased product yield
Cleanroom for Food Packaging Process
Location: Compton, California
Application: Achieving USDA Compliance in Mixing and Packaging
Product: PortaMax 458 XTRA TALL Wall System
Benefits Provided:
- Quality control
- USDA compliance
- Improved product yield
Cleanroom for Medical Device Manufacturing
Location: Winston-Salem, NC
Client: Wilson Cook Medical
Product: PM458 XTRA TALL Wall System (20,000 sq ft)
Benefits Provided:
- Capability to achieve cleanliness and air quality standards
- Flexibility to relocate
- Minimal disruption and speed of construction
Cleanroom for Medical Device Packaging
Location: Clearwater, MN
Client: T.O. Plastics
Product: Series 300 Panels with Anondized-Aluminum Framework FRP (Fiberglass Reinforced Plastic)
Benefits Provided:
- Cleanability
- Recirculating air flow to meet ISO standards
- Pass-through chamber to maintain cleanroom integrity
Cannabis Cultivation Room Case Studies
Two-Story Cleanroom with a High Bay for Cannabis Cultivation
Application: Cannabis Cultivation Facility
Location: Denver, CO
Product: Series 300 with aluminum framework and insulated panels
Benefits:
- Fast and clean installation that resulted in faster permit and license obtainment
- Load-bearing structural system that allowed for high bays with an integrated racking / growing system
